Products and method for packaging multiple rows of products

ABSTRACT

A method and system are described for providing supports for multiple rows of stacked goods with edge protectors that can be separated at predetermined zones to allow one row of stacked goods to be readily separated from another row. Also described are separable edge protectors for use with the method and system. Also described is a method and system for providing customized packaging adapted for specific goods.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 61/298,254 filed Jan. 26, 2010 and U.S. Provisional Patent Application Ser. No. 61/409,534 filed Nov. 2, 2010.

BACKGROUND OF THE INVENTION

The present disclosure relates to products and methods for packaging goods and methods and systems for customizing protective packaging for specific goods.

Packaged goods, particular those in containers such as cardboard or linerboard boxes, are frequently stacked in multiple rows. Containers such as cardboard or linerboard boxes, wooden crates, plastic bins, and the like may be stacked in a plurality of rows, optionally on a pallet or slip sheet, and then secured together with an overwrap such as stretch wrap or other securement means to form a unit load for convenient handling in transportation. Handling may be done by a clamp truck or forklift, for example. Without additional protection, products in unit loads may be damaged during handling, especially due to forces applied to the corners or sides of the unit load. Products may also shift or slide in the unit stack without additional stabilizing means. Corner protectors such as the VBoard® Corner Protectors by Laminations (Appleton, Wisconsin), a subsidiary of Great Northern Corporation (Appleton, Wisconsin) provide rigid, protective guards on corners that also stabilize the containers in a unit load and reduce the risk of damage or unwanted shifting or falling of products during handling. In some cases, corner guards may also provide longitudinal support for increased stacking strength in addition to providing increased support for enhanced resistance to vertical and lateral crushing at the corners of the container.

Such corner protectors are typically put in place before or during application of an overwrap such as stretch wrap and are held firmly in place by the overwrap. When the unit load reaches its destination such as a distribution center, warehouse, or backstore of a retail establishment, the overwrap and corner protectors are first removed to allow removal of product containers, typically by removing one or more rows or one or more individual containers. Removal using clamp trucks or other equipment can result in crushing of the containers, especially when an entire row needs to be removed from the top of a unit load or a stack of unit loads. Moving the entire row without protective corner protectors and protective wrap can also result in damage to corners, tipping, shifting, or falling of individual containers, and other forms of damage to the goods. This can be in part due to the absence of all or part of the overwrap from the remaining portion of the unit load, since the overwrap can provide structural support and stability for the unit load, particularly in cooperation with corner guards.

SUMMARY OF THE INVENTION

A separable edge protector has been developed which can protect the edges of a unit load having a plurality of rows, such as two or more rows of cartons, boxes, or other stacked goods in the unit load. The separable edge protector has one or more zones of weakness such as perforations or slits in the material thereof such that it can be fractured or broken apart when rows of product within the unit load are separated by equipment such as a clamp truck, wherein the portions of the edge protector can remain intact with the divided portions of the unit load to continue providing edge protection. In some embodiments, the separable edge protector is tailored for the unit load being handled such that upon properly placing the separable edge protector in contact with the unit load, the zones of weakness are only present in regions corresponding to the breaks between layers of product. In this manner, the sections of the separable edge protector that remain in contact with a layer of products after separation from other layers can be free of perforations and provide higher stacking strength. Thus, separated rows of product can be stacked and handled with greater protection than would be otherwise possible (e.g., in contrast to separated rows without separable edge protector that remain in place, or in contrast to separable edge protectors with zones of weakness at redundant locations therein or in locations that do not correspond to breaks between rows of product in the original unit load.

The separable edge protector as applied to an outer surface of a unit load has an initial length L and is subdivided by one or more zones of weakness into two or more subsections. The separable edge protector has at least one zone of weakness such as a line of perforations substantially proximal to the break between two adjacent rows (e.g., two vertically adjacent rows in a unit load), such that a force applied to separate the two adjacent rows can also detach the separable edge protectors at the zone of weakness, such that one section moves away with the separated row and the other section remains in place with the remaining row or rows of the unit load to continued providing protection. The separable edge protector thus has at least two subsections joined at a zone of weakness where the two subsections can be separated one from another responsive to a force applied to the separable edge protector to yield two shortened sections of edge protectors.

The separable edge protectors may be in the form of angle protectors (sometimes called corner posts) that protect angled portions of a unit load at the four vertical corners of a unit load comprising containers with rectangular cross-sections. Such angle protectors generally have a longitudinal axis, an apex along the longitudinal axis from which respective first and second legs extend, the first and second legs being at about a 90-degree angle (or other suitable angle) to each other. While the cross-section of many angle protectors generally has the appearance of a “V” or “L” more complex shapes are possible. The thickness of the legs can be uniform or nonuniform, and may range, for example, from about 060 inches to about .500 inches (1.5 mm-12.7 mm).

The separable edge protectors may be made from laminates of paper and other materials held in place with adhesives such as glues, hot melts, and the like; from molded paper pulp; from extruded composites such as fiber and resin mixtures; from sheet metal or other metallic elements; from injection molded plastic or other plastic components; from aluminum foil paper or composites; and from combinations thereof.

In one aspect, an improved unit load system has been developed comprising a unit load having two or more rows and at least one separable edge protector attached to an outer edge of the unit load, the separable edge protector having a zone of weakness proximal to the break between at least two or the two or more rows, the zone of weakness being adapted to cause the separable edge protector to break into two subsections in response to a force that removes at least one row from the unit load, wherein a subsection of the separable edge protectors remains in place with the remaining portion of the unit load after the at least one row is removed. More than one separable edge protector may be used, such as two or more, three or more, or four or more separable edge protectors.

In another aspect, a method of protecting shipments is disclosed in which customized separable edge protectors are provided in response to the needs of customer preparing a unit load with two or more rows of containers having a characteristic height. The separable edge protectors are provided with zones of weakness spaced apart by a distance substantially equal to the characteristic height of the rows, such that when a separable edge protector is placed on a vertical face of unit load made of the containers having the characteristic height, the zones of weakness in the separable edge protectors will be substantially proximal to the breaks between the rows in the unit load. The method in one version comprises:

(a) receiving product information from a customer for a planned unit load identifying the elevations in the unit load of one or more breaks between rows of a stack of products;

(b) preparing customized separable edge protectors having zones of weakness corresponding to the elevations in the unit load when the separable edge protectors are in place on an outer surface of the unit load;

(c) delivering the customized separable edge protectors for use in a packaging facility; and

(d) applying one or more customized separable edge protectors to a stack of the products to form a protected unit load

The method may further comprise applying an overwrap before or after adding the one or more customized separable edge protectors.

The method may comprise applying perforations to an edge protector such as a corner guard made of a paper-based or fiber-based laminate, the perforations being made responsive to the product information received from the customer.

The method may further comprise delivering a separable edge protector manufacturing device proximal to a packaging facility of a customer to prepare customized separable edge protectors on demand. A mini-mill or converting facility may be used for manufacturing, which may comprise receiving base edge protectors that are then converted into separable edge protectors by adding zones of weakness in predetermined locations responsive to customer information about planned unit loads.

Zones of weakness may be created in rigid materials suitable for use as edge protectors by any suitable means. Zones of weakness may be built into a material during manufacturing such as by depositing a zone of relatively lower basis weight in a molded fiber material, or by adding a chemical debonder or other weakness-inducing additive to a fiber-based material during manufacturing. Alternatively, a substantially uniform material suitable for use as an edge protector may be converted into a separable edge protector by converting steps that remove material or weaken existing material. Useful method for adding a zone of weakness can include perforation, laser ablation, water jet cutting (e.g., high-pressure, high-velocity water jets that cut a potion of a rigid material), drilling, sawing, burning, thermal decomposition, scoring, mechanical ablation, grinding, and the like.

In another aspect, a method of separating portions of a unit load is provided. In this method, one or more separable edge protectors are attached to a unit load spanning at least two rows of product in the unit load, a break being defined between two adjacent rows of the at least two rows of product that is proximal to a zone of weakness in each of the one or more separable edge protectors. A motive force is then provided to the uppermost of the two adjacent rows to cause separation of the two adjacent removes by removing the uppermost of the two adjacent rows, wherein the motive force causes the separable edge protectors to detach in the zone of weakness proximal to the break, leaving a portion of the separable edge protector in place providing edge protection for the remaining rows of product in the unit load.

The separable edge protectors can be constructed, for example, using known methods of producing angle protectors coupled with processing to create zones of weakness at specific locations adapted for use with the row heights for specific types of unit loads. Such processing can include perforating, laser ablating, water jet cutting, and the like. The materials to be processed to have zones of weakness for use according to various embodiments disclosed herein can include the VBoard® line of products by Laminations (Appleton, Wis.), a subsidiary of Great Northern Corporation.

The separable edge protectors can be placed onto a unit load by hand or with the assistance of automated equipment. An example of an automated device for applying edge protectors to packaging is provided in U.S. Pat. No. 5,226,280, “Apparatus for Placing Corner Protectors Onto Palletized Loads,” issued Jul. 13, 1993 to P. G. Scherer and W. K. Diehl, herein incorporated by reference to the extent that it is noncontradictory herewith. Another example is U.S. Pat. No. 7,213,381, “Apparatus for Applying External Corner or Edge Protectors Onto External Corner or Edge Regions of Packages or Palletized Loads,” issued May 8, 2007 to M. Zitella and F. Turfan, herein incorporated by reference to the extent that it is noncontradictory herewith. Zitella and Turfan describe an apparatus for placing external corner protectors upon the external corner regions of palletized loads, prior to the wrapping of the palletized loads with wrapping material.

Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings illustrate the best mode presently contemplated of carrying out the disclosure. In the drawings:

FIG. 1 depicts a separable edge protector;

FIG. 2 depicts several embodiments of separable edge protectors showing different configurations for zones of weakness;

FIG. 3 depicts a unit load with separable edge protectors in place having zones of weakness corresponding to breaks between rows of products in the unit load;

FIG. 4 depicts the unit load of FIG. 3 after application of a motive force to separate the upper row from the lower row;

FIG. 5 depicts a knife for perforating V-shaped edge protectors to form separable edge protectors;

FIG. 6 depicts another cross-sectional shape for a separable edge protector;

FIG. 7 depicts a process for providing customized separable edge protectors fro use in a packaging facility;

FIG. 8 depicts a unit load protected with separable edge protectors and having an overwrap of stretch wrap being separated into two sections by a clamp truck;

FIG. 9 depicts a stretch wrap applicator for use with some embodiments described herein;

FIG. 10 depicts one version of a manufacturing unit for producing a laminated V-shaped board for use in forming separable edge protectors;

FIG. 11 depicts one version of a shaping process to impart a suitable cross-sectional shape to a multilayer board;

FIGS. 12A, 12B, and 12C depict cross-sectional shapes of a multilayer board as it is processed in various stages to transition from a flat board to a nearly 90° angle V-shaped board; and

FIG. 13 depicts a perforating system for imparting zones of weakness into V-shaped boards and other corner protection materials.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 depicts a perspective view of separable edge protector 20 comprising a first leg 22 and a second leg 24 joined at an apex 26 with an angle θ therebetween which may be approximately 90 degrees or other suitable angle depending on the geometry of the unit load and the containers therein. Each leg 22, 24 has a respective width W1, W2 and a thickness T (the thickness need not be identical for the two legs 22, 24 and can vary across either or both legs, as desired). The separable edge protector 20 has a length L and a first end 28 and an opposing second end 30.

A zone of weakness 34 is disposed at a distance L1 from the first end 28, dividing the separable edge protector 20 into a first subsection 40 and a second subsection 42. The two subsections 40, 42 are joined together, maintaining structural integrity of the separable edge protector and providing the ability to resist longitudinal compressive forces and offer protection to the corner (not shown) of a unit load (not shown) that the separable edge protector 20 engages and protects. However, in response to a sufficiently large lateral shearing force or longitudinal tension, the zone of weakness 34 is design to cleanly fail, causing the separable edge protector to be divided into two separate sections approximately of lengths L1 and L2, corresponding to subsections 40, 42.

The zone of weakness 34 as shown comprises a plurality of perforations 36 which extend across portions of both legs 22, 24. The number and size of the perforations can be varied to achieve desired results as a function of the strength and thickness of the material used to make the separable edge protector 20, as well as the detachment criteria for the intended use or the nature of the products in the unit load (not shown) and the equipment (not shown) to used in handling the unit load and causing detachment of one subsection 40, 42 from another.

In one embodiment, the distance L1 corresponds to the height of a row of products (not shown) in a unit load, such that when the first end 28 of the separable edge protector 20 is approximately aligned with the top of a unit load (not shown), the zone of weakness 34 will be approximately aligned with a break beneath the top row of products in the unit load, such that removing the top row causes the zone of weakness 34 to fail and allow the first subsection 40 to be removed with the row of products without the need for manual cutting or breaking of an edge protector and in some embodiments without the need to cut or remove an overwrap (not shown).

In one embodiment, each zone of weakness 34 in a separable edge protector 20 attached to a unit load (not shown) corresponds to a break between rows of products (not shown) such that zones of weakness 34 that are not potentially needed to facilitate removal of individual rows of product are avoided. In this manner, higher strength can be provided in the separable edge protector 20 by avoiding redundant zones of weakness 34. It should be understood that in general, the separable edge protector 20 may be suited to span the entire height of a unit load (not shown) and may have more than one zone of weakness 34 corresponding with the locations of the breaks (not shown) between rows of containers (not shown) in the unit load.

FIG. 2 shows a related separable edge protector 20 with three zones of weakness 34A, 34B, 34C depicting alternate embodiments for their location and characteristics. A first zone of weakness 34A defines paths 52A, 54A that are not normal to the longitudinal axis 49 of the separable edge protector 20 but in this case as depicted is generally at an angle other than 90 degrees to the longitudinal axis 49 across both legs 22, 24. The first zone of weakness 34A defines a first subsection 40 of length L1 measured along the apex 26.

The second zone of weakness 34B has a non-linear shape with curved paths 52B, 54B in both legs 22, 24, respectively. A third zone of weakness 34C is depicted with broader segments 52C, 54C in both legs 22, 24, respectively, wherein the segments 52C, 54C are generally normal to the longitudinal axis 49. The three zones of weakness 24A, 34B, 34C divide the separable edge protector 20 into four connected subsections 40, 42, 44, 46 of lengths L1, L2, L3, and L4, respectively, as measured along the apex 26.

Zones of weakness 34A and 34B are depicted as perforations, while the third zone of weakness 34C is depicted as a broader zone of weakness due created by other means such as use of lower basis weight in the material of the separable edge protector 20, or needling, laser ablation, scoring, or other methods.

It is recognized that in some embodiments, the use of different designs and manufacturing methods for the zone of weakness 34A, 34B, 34C in a single separable edge protector 20 may not be practical, and that the specific configurations shown in FIG. 2 were largely selected to illustrate some of the possibilities. Nevertheless, there may be cases when various differences in the characteristics and manufacturing methods for multiple zones of weakness 34A, 34B, 34C in a separable edge protector 20 or in the various separable edge protectors 20 used for a single unit load (not shown) may be useful.

FIG. 3 depicts a perspective view of a unit load 50 comprising a stack of products 58 having a lower row 64 and an upper row 60 placed on a pallet 80. The upper row 60 comprises four products 62 packed in rectangular boxes or product containers generally having a rectangular cuboid (parallelepiped) shape, though any suitable shape and number of products per row can be used. The lower row 64 comprises ten products 66 of different size than the upper row 60. At the four vertical corners 68A, 68B, 68C, 68D of the unit load 50 (or more specifically, at the four vertical corners defined by the stack of products 58) are disposed four separable edge protectors 20A, 20B, 20C, 20D, respectively, held in place by bands 70A, 70B, 70C that extend around all four vertical faces 53A, 53B, 53C, 53D of the unit load 50. (Alternatively but not shown, a wrap covering substantially all four faces 53A, 53B, 53C, 53D and part or all of the upper surface 55 of the unit load could be used, such as stretch wrap or shrink wrap.)

Each separable edge protector 20A, 20B, 20C, 20D has a first end 28 adjacent or toward the upper surface 82 of the pallet 80 and an opposing second end 30 away from the pallet 80 and, in this embodiment, proximal to the plane of the upper surface 55 of the unit load. The first end 28 need not contact or be adjacent the pallet 80, but could be (not shown) at a greater elevation, such as 5 cm or more, 10 cm or more, or 15 cm or more above the upper surface 82 of the pallet 80. Likewise, in an alternative embodiment (not shown), the second end 30A. 30B, 30C, 30D need not aligned with the upper surface 55 of the unit load 50, but could be above or below the upper surface 55 by any suitable distance, such as about 1 cm or more, about 5 cm or more, about 10 cm or more, or about 15 cm or more, such as from 2 cm to 20 cm or from 5 cm to 15 cm. As shown, separable edge protectors 20B and 20D each have a second end 30B, 30D, respectively, substantially aligned with the upper surface 55 of the unit load 50, whereas separable edge protector 20A has a second end 30A slightly below the upper surface 55 and separable edge protectors 20C has a second end 30C slightly above the upper surface 55 of the unit load 50.

The pallet 80 can be according to any known pallet system, but in the simplified form shown here is depicted as having an upper surface 82 defined by three upper panels 84A, 84B, 84C joined to three cross beams 86A, 86B, 86C connected to three lower panels 88A, 88B, 88C. Alternatively but not shown, slip sheets or other supports could be used, or the stack of products 58 could be assembled in a unit load 50 without an underlying structure, or optionally with additional edge protectors under the lower horizontal edges of the stack. Also alternatively but not shown, the separable edge protectors 20A, 20B, 20C, 20D may also extend over at least part one or more the outer corners of the pallet 80, if desired. Also alternatively but not shown, additional corner protectors, including additional separable edge protectors, could extend over at least part of one or more of the upper horizontal corners of the stack of products 58. Other protectors, cushions, pads, reinforcing elements, slip sheets, etc. (not shown) could also be positioned on any face of the stack 58 or between the rows 60, 64 or between individual products 62, 66.

The horizontal dimensions of the stack of products 58 may be smaller than the respective dimensions of the pallet 80, as shown, or, in alternative embodiments not shown, the stack of products 58 may have substantially the same horizontal footprint as the upper surface 82 of the pallet 80, or the stack of products 58 or extend beyond the edges of the pallet 80 in at least one dimension.

The bands 70A, 70B, 70C may be provided in any number and form other than those shown here. Greater or smaller numbers of bands 70A, 70B, 70C may be used, and additional vertically oriented bands (not shown) may extend over two opposing vertical faces of the stack of products and also over the upper surface 55 of the stack of products 58, though for ease of separation of the upper row 60 from the lower row 64, it may be useful to remove any vertically oriented bands (not shown) before carrying out the separation.

With the configuration of the unit load 50 shows, the upper row 60 of products can be removed from the unit load 50 without the need to cut the bands 70A, 70B, 70C (or, if an overwrap such as stretch wrap were in place, without the need to cut or remove the stretch wrap) and without the need to manually detach individual separable edge protectors 20A, 20B, 20C, 20D. Removal of the upper row 60 can be readily accomplished by applying a force to opposing sides of the upper row 60, such as by a clamp truck (not shown) with the clamps raised to the appropriate height to grasp the upper row 60 without also grasping the lower row 64. A force is then applied to move the upper row, depicted here as a force vector 90 with a predominantly vertical oriented and a lateral component as well so the force vector 90 is not strictly vertical, though it could be substantially vertical or substantially lateral, if desired. The applied force causes each of the separable edge protectors 20A, 20B, 20C, 20D to separate in each respective zone of weakness 34, leaving the first section 40 of each separable edge protector 20A, 20B, 20C, 20D to remain in place with the low row 64 of products 66 and allowing the second sections 42A, 42B, 42C, 42D, respectively, of each separable edge protector 20A, 20B, 20C, 20D to remain in place with the upper row 60 of products 62 as they are moved away from the unit load 50, as shown in FIG. 4. The first section 40 of each separable edge protector 20A, 20B, 20C, 20D can thus continue to protect the sides of the remaining portion of the unit load 50.

As depicted, the separable edge protectors 20A, 20B, 20C, 20D are substantially free of zones of weakness 34 except where needed proximal to the break 72 between the upper row 60 and lower row 64 of products 62, 66. In such embodiments, in general, the number of zones of weakness 34 in each separable edge protector 20A, 20B, 20C, 20D is no greater than the number of breaks 72 in the stack of products 58, such that for a stack of products 58 with two rows 60, 64, there is one zone of weakness 34, but if there were, say, four rows of products (not shown), there could be three zones of weakness 34 or less, such as one, two, or three, with the location of each zone of weakness 34 generally being proximal to a corresponding break 72 in the stack of products 58.

Referring back to FIG. 4, the second sections 42A, 42B, 42C, 42D of the separable edge protectors 20A, 20B, 20C, 20D, respectively, are free of zones of weakness 34. The row 60 is handled in a distribution center, warehouse, truck, or back room of a store, for example, it can be stacked and moved, with the attached second sections 42A, 42B, 42C, 42D in place to provide not only edge protection but also good stacking strength when stacked with other goods (not shown). Unit loads 50 are frequently broken down into smaller subunits such as the upper row 60 shown and then handled separately, including being stacked. The ability to have continued edge protection and/or good stacking strength provided by the separated second sections 42A, 42B, 42C, 42D or other sections of the separable edge protectors 20A, 20B, 20C, 20D can, in some embodiments, helpful relative to embodiments in which redundant zones of weakness 34 are present.

FIG. 4 depicts the unit load 50 of FIG. 3 after the upper row 60 has been removed from the unit load 50 and separated from the lower row 64 thereof due to application of a motive force 90. The separable edge protectors 20A, 20B, 20C, 20D of FIG. 3 have now fractured into first sections 40A, 40B, 40C (not visible), 40D that remain to protect the unit load 50 on the pallet 80, while the separated second sections 42A, 42B, 42C, 42D remain with the separated upper row 60.

FIG. 5 depicts a portion of a perforating device 100 for perforating a V-shaped edge protector 20 to provide the customized zones of weakness 34 for various embodiments disclosed herein. The separable edge protector 20 is oriented normal to the plane of the drawing, showing a cross-section of the body 120 of the separable edge protector 20 as it passes over a contoured support element 130. A knife 106 having an edge 108 is held my a knife holder 104, which in turn is driven by a ram (not shown) such as a hydraulic ram, pneumatic ram, or other driving means to move the knife 106 in a path of motion 126 that is generally up and down.

When the knife 106 is driven downward, it can cut into the body 120 of the separable edge protector 20, passing through the body 120 and into a recessed receiving slot 132 in the contoured support element 130.

The knife 106 comprises a series of spaced about notches 110 wherein the material of the knife 106 has been removed such that the portions having the notches 110 do not cut through the body 120 of the separable edge protector 20 (or, in some embodiments, leave the body 120 largely undisturbed in the region immediately below the notches 110). Between the notches are teeth 112 corresponding to the original knife edge 108 before the notched regions were removed. The teeth 112 have a depth D and a width T and are spaced apart according to the width of the notches N. Teeth 112 for perforating the body 120 of the separable edge protector 20 are present over both the first leg 22 and the second leg 24 of the separable edge protector 20, but in this version are absent directly over the apex 26, a notch is present instead to keep the apex 26 intact, though this is not necessary in other embodiments.

The number of teeth 112, the dimensions T, W, and D, and other geometrical and processing considerations for the perforation process can be optimized and varied in many ways. In operation, the body 120 may be automatically move into place such that the location of the zone of weakness 34 to be created corresponds to specifications from customer data or other information sources pertaining to the final characteristics of the separable edge protector 20. Once in place, the ram (not shown) drives the knife holder 104 and the knife 106 down into the body 120 of the separable edge protector 20 to create perforations defining a zone of weakness 34. The body 120 can then be further advanced normal to the place of the drawing to put it into place for a subsequent zone of weakness 34 to be created by perforation. This can be done on a boy 120 that is already cut to the desired length on a long body 120 prior to cutting to length. Perforating and cutting can also be done simultaneously, if desired. Perforating or other converting operations can also be conducted on site, such as in a packaging facility shipping out unit loads, wherein the converting is done on demand based on date pertaining to current packaging operations to ensure that suitable positioned zones of weakness 34 are provided on the separable edge protectors 20 as they are made available for packaging or shortly before use in packaging. An alternative process is to conduct the perforating or other creation methods for making zones of weakness 34 at a remote manufacturing facility (not shown) such as that owned by the provider or manufacturer of the body 120 of the separable edge protector 20, and then receiving customer input data to guide customization of the separable edge protectors 20, which are then shipped to the location (not shown) where they are needed for a particular product or batch of products (not shown).

FIG. 6 depicts a cross section of a separable edge protector 20 having a substantially rounded shape, here in a form resembling an annulus with a quarter section removed capable of receiving the corner 63 of a product 62. The geometry of the separable edge protector 20 can encompass many other designs outside the scope of flat legs joined at an apex (not shown).

FIG. 7 depicts the flow of operations 200 in a method of customizing separable edge protectors for use in unit loads for a customer. In step 210, a manufacturer input from a customer based on considerations 230 from the customer's operation pertaining to the build of the unit load, product specifications (e.g., container types, crush load, stacking capacity, etc.), as well as shipping considerations and intended destinations and conditions or practices there. This information can be provided or stored at least in part electronically via entry to a computer system comprising or in electronic communication with S.E.P. server 240 for use with systems related to producing customized separable edge protectors (S.E.P.s).

In step 212, the manufacturer determines suitable properties for the separable edge protectors based onto the input received from the customer in step 210. Then in step 214, recommendations for suitable separable edge protectors are submitted to the customer for review and approval or modification 232, if necessary. Electronic files and feedback may be transmitted in this step with assistance of the S.E.P. server 240 which may store and upload or download files useful for the review and approval process. Once the design is approved in step 214, the manufacturer in step 216 prepares the manufacturing equipment to create the separable edge protectors needed by the customer. The locations and characteristics of the zones of weakness in particular can be programmed into manufacturing equipment in this step, and needed raw materials and hardware can be prepared (e.g., selecting the proper perforating knife that will be controlled by the programmed equipment in creating the customized separable edge protectors). The program information can be stored in a manufacturing database 234 in communication with the S.E.P. server 240 that are in communication with the manufacturing hardware (not shown) to assist in driving and controlling operation of the hardware according to the programmed instructions, which are stored in memory in the manufacturing database or on the S.E.P. server.

In step 218, the manufacturing equipment is deployed to convert feedstock such as unperforated V-shaped corner protectors into separable edge protectors responsive to the programmed instructions in memory, which in turn are responsive to the input received from the customer. An interface for the manufacturing system 236 driven by or in communication with the S.E.P. server 240 and the manufacturing database 234 can assist in executing the manufacturing program and preparing the desired customized separable edge protectors.

In step 220, the customized separable edge protectors are then delivered to the customer. In step 220, the separable edge protectors are attached to unit loads that are composed of products and/or containers similar to or identical to those specified in step 210. Typically, the zones of weakness in the separable edge protectors should be aligned with row breaks in the unit loads. Overwrap or strapping may be applied, or other means for holding the separable edge protectors in place such as adhesive materials can be used. The protected unit loads with the separable edge protectors in place are then shipped to their respectively destinations in step 222, where the unit loads can be stored and eventually or as needed broken down by rows, if desired, using motive force to separate rows while keeping edge protectors in place on the remaining portion of the unit loads to continue providing protection and integrity to the stack of products.

FIG. 8 depicts a unit load 50 encased in stretch wrap 71 in an embodiment related to that of FIG. 3. The unit load 50 has been split into an upper row 60 and a bottom section 65 comprising 3 lower rows 64A, 64B, 64C of products 58, and both the upper row 60 and the bottom section 65 remain encased in the stretch wrap 71 which has been severed as shown with the separation of the upper row 60. The upper row 60 has been separated from the lower section 65 due to application of a motive force 90 applied by the clamps 91 of a clamp truck 93 causing the unit load 50 with the stretch wrap 71 to split. The split occurred substantially at a first zone of weakness 34A in the original separable edge protectors 20A, 20B, 20C (not visible), 20D substantially aligned with original juncture of the upper row 60 with the upper surface 57 of the lower section 65. The separable edge protectors 20A, 20B, 20C, 20D have thus fractured to release second sections 42A, 42B, 42C, 42D that remain with the separated upper row 60 while first sections 40A, 40B, 40C (not visible), 40D remain with the lower section 65. The first sections 40A, 40B, 40C (not visible), 40D still have additional unfractured zones of weakness 34B, 34C substantially corresponding in location, respectively, to breaks 75B, 75C above the lower rows 64B, 64C of products 58 (i.e., break 75B is between rows 64A and 64B, and break 75C is between rows 64B and 64C).

In the embodiment shown, the separable edge protectors 20A, 20B, 20C (not visible), and 20D are free of zones of weakness that do not correspond to breaks between rows of products, thus ensuring that the separable edge protectors 20A, 20B, 20C (not visible), and 20D have higher strength than if they were perforated at additional unneeded locations. In the upper row 60, now that it has been separates as an individual row of products 58, the attached sections of separable edge protectors (the second sections 42A, 42B, 42C, 42D) are free of perforations in the bodies thereof and thus can offer high stacking strength and durability. By only providing perforations where needed for the separation of individual rows, improved protection is provided.

FIG. 9 depicts a stretch wrap applicator 250 for applying stretch wrap 252 to a stack 254 of products 58 to form a unit load 50. The stretch wrap applicator 250 in the embodiment shown comprises a rotating platform 256 which rotates the stack 254 in the direction of arrow 278 as stretch wrap 252 is deployed and wrapped around the stack 254. A worker 260 places separable edge protectors 20 against the unit load 50 such that each separable edge protector is restrained by the stretch wrap 252 and locked in place. Zones of weakness 34 in the separable edge protectors 20 are substantially aligned with the breaks 75 between rows of product 64A, 64B in the stack 254. Successive layers of stretch wrap 252 can be applied to secure the separable edge protectors 20 and further protect the unit load 50. In the embodiment shown, a roll 264 of stretch wrap 252 is mounted on a platform 278 with a slidable support 272 that can move vertically in a track 270 within the stretch wrap applicator 250. In this manner, stretch wrap 252 can be applied to build unit loads 50 of varying height. The stretch wrap applicator 250 can also be programmed to vary the application of the stretch wrap 252 (e.g. the number of layers applied) as a function of height. In some versions, for example, the stretch wrap 252 may be relatively thinner (fewer layers applied) near a break 75 between rows 64A, 64B to facilitate separation of the stretch wrap 252 when a layer 64A is removed from the unit load 50, while still securing the layer 64A and the portions of the separable edge protectors 20 that will be removed with the layer 64A.

FIG. 10 depicts a manufacturing unit 300 for producing a laminated V-shaped board 320 that can be used to form edge protectors. As depicted, three paper rolls 302A, 302B, 302C supply paper webs 304A, 304B, 304C moving generally in the direction shown by the arrow 340 (i.e., from left to right). The upper surfaces of the two lower paper webs 304B, 304C are coated with adhesive 308 supplied from adhesive applicators 306A, 306B. The adhesive 308 may be a water-based glue applied by metering, blade coating, or any other known coating or application method. Alternatively, the adhesive 308 may be a melt adhesive, a spray melt, or other adhesives applied by spray systems (not shown) or other systems known in the art. The paper webs 304A, 304B, 304C are brought into contact as they pass between two opposing rolls 310A, 301B such that bonding between the paper webs 304A, 304B, 304C occurs to form a multilayer board 312. The multilayer board 312 then passes through a shaping unit 314 to impart a V-shape using systems such as that described in FIG. 11 hereafter, and further passes through a curing unit 316 in which energy is applied to further cure the adhesive 308. Additional shaping treatments may be applied through various means such as opposing vertex shaping rolls 318A, 318B that may sharpen the apex of the resulting V-shaped board 320. The V-shaped board 320 may then be subject to further operations (not shown) such as perforation, coating, edge treatments, addition of pressure-sensitive adhesive panels, and the like.

FIG. 11 in combination with the cross-sections shown in FIGS. 12A, 12B, and 12C depicts one version of a shaping process to impart a suitable cross-sectional shape to a multilayer board 312 as it travels in the direction shown by the arrow 340. Preferably while adhesive (not shown) within the multilayer board 312 has not yet fully cured, the multilayer board 312 contacts a first set of opposing shaping rolls 322A, 324A which begin adding a V-shape as shown in the cross-section of FIG. 12A. Further shaping occurs through the action of a second set of opposing shaping rolls 322B, 324B, resulting in a more highly angled cross-section of the V-shaped board 320 as shown in FIG. 12B, and further shaping still occurs through the action of a third set of opposing shaping rolls 322C, 324C, resulting in a V-shaped board 320 having an internal angle of approximately 90 degrees as shown in FIG. 12C. The resulting V-shaped board 320 can then be perforated, cut, and further processed as desired (not shown).

FIG. 13 depicts an automated perforating system 400 comprising a perforating head 402 having an portal 404 through which the perforated V-shaped board 320 exits the system. In the portal 404 is a first shoe 406 that hold the V-shaped board 320 in place. A user (not shown) places a first end 420 of a cut section of the unperforated V-shaped board 320 on the first shoe 406 and a second end 422 of the V-shaped board 320 is placed on a second shoe 408 attached to a sliding push unit 430 that is driven by a computer controlled drive (not shown) within a chassis 432. The drive (not shown) may be a linear belt drive, a chain drive, a gear drive, or any other drive system.

An orthogonal view into the portal 404 may display the perforating device 100 shown in FIG. 5. The first show 406 may substantially correspond to the contoured support element 130 of FIG. 5 or may be an additional support in front or extending from the contoured support element 130 of FIG. 5.

After an unperforated section of V-shaped board 320 has been perforated at one or more locations along its length, it is removed from the perforating system 400. Examples of the perforated product include the perforated V-shaped board 321 with two zones of weakness 34A (perforated regions) shown adjacent the chassis 432. To illustrate that corner protectors of various cross-sectional shapes can be perforated with the perforating system 400, also shown is a perforated section of a three-lobed corner protector 323 that has two zones of weakness 34B imparted by the perforating system 400.

The perforating system 400 includes a control interface 440 that allows operators (not shown) to set details of the perforation operation. The control interface 440 may also be in communication with a database (not shown) of information regarding product specifications for particular clients to ensure that the desired customization of the perforations are applied to create perforated v-board sections 321 that have zones of weakness 34A in the proper locations corresponding to rows of product (not shown) when used as a separable edge protector. Communication may include transmission of information over the Internet or other means. Identifying indicia such as bar codes, QR codes, electronic ID in RFID tags or related remotely readable tags, or other information may be associated with or applied to the perforated products 321, 323 to assist in automated processing and logistics further down in the supply chain. Such information can help assure that properly perforated products are used for the intended unit loads (not shown) and that such unit loads are handled in the right way (e.g., clamp trucks pick up and break off rows of product in the right manner for successful operation with the perforated v-board 321, for example, serving as a separable edge protector).

The separable edge protectors can be prepared using any known method for corner protectors, followed by or including steps to add suitable zones of weakness at predetermined locations adapted for rows of specific height. For example, construction could be conducted generally according to U.S. Pat. No. 5,799,797, “Corner Post Construction,” issued Sep. 1, 1998 to R. G. Braun, herein incorporated by reference to the extent that it is noncontradictory herewith. U.S. Pat. No. 5,799,797 discloses a corner post construction for containers, such as boxes and cartons, which may be fabricated from materials such as corrugated paperboard material. The corner post construction is provided by fabricating a substantially planar sheet of material, having a longitudinal axis, and bending the sheet of material along a fold line which is substantially parallel to the longitudinal axis, so that there are two corner post wings formed, with an included angle formed between them. A corner post reinforcing and retaining material is disposed along the fold line which maintains the corner post wings in substantially fixed angular relation to one another.

In one method, similar to that of FIGS. 10-13, rolls of paper are used to provide multiple layers that are treated with adhesive, brought together before the adhesive cures, bent into a predetermine shape using, for example, shaped molding boards, shaped roller wheels, mechanical presses, or other means to impart a suitable cross-sectional shape such as an L-shape or V-shape to a the laminate. The laminate can then be cured with heat, time, or other means, and cut to suitable lengths and perforated or otherwise treated to create zones of weakness at predetermined locations corresponding to the packaging needs of a customer, such that the zones of weakness can be readily aligned with one or more breaks between the rows of products in a unit load. The steps of laminating, shaping, curing, cutting, and perforating or otherwise creating zones of weakness can be done in any suitable order or simultaneously, when suitable. For example, perforations or laser ablation can be done during curing or during cutting, as can cutting. Shaping can also be done as layers are brought together or during curing or both.

Having described aspects of the invention in detail, it will be apparent that modifications and variations are possible without departing from the scope of aspects of the invention as defined in the appended claims. As various changes could be made in the above compositions, products, and methods without departing from the scope of aspects of the invention, it is intended that all matter contained in the above description shall be interpreted as illustrative and not in a limiting sense.

While the foregoing description makes reference to particular illustrative embodiments, these examples should not be construed as limitations. The inventive system, methods, and products can be adapted for other uses or provided in other forms not explicitly listed above, and can be modified in numerous ways within the spirit of the present disclosure. Thus, the present invention is not limited to the disclosed embodiments, but is to be accorded the widest scope consistent with the claims below. 

1. A unit load comprising: a plurality of products stacked in a plurality of rows with breaks therebetween; and at least one separable edge protector attached to at least one side of the unit load, the separable edge protector having a length that spans at least an upper row and an adjacent lower row of the plurality of rows, the at least one separable edge protector including a zone of weakness proximate to a break between the upper and lower rows of products, wherein the zone of weakness of each of the at least one separable edge protectors is adapted to separate in response to the act of separating the upper row of products away from the lower row.
 2. The unit load of claim 1, wherein the separable edge protector is attached to the unit load by a flexible wrap surrounding at least part of the unit load.
 3. The unit load of claim 1, wherein the unit load has four corners, and wherein the separable edge protectors are provided along each of the four corners.
 4. The unit load of claim 1, wherein the at least one separable edge protector comprises a plurality of zone of weakness, each zone of weakness being generally aligned with a break between adjacent rows.
 5. The unit load of claim 1, wherein the at least one separable edge protector is free of zones of weakness other than those proximal to the breaks between the rows of product.
 6. The unit load of claim 1, wherein the separable edge protector comprises a laminate having a plurality of fibrous layers.
 7. The unit load of claim 1, wherein the separable edge protector comprises molded pulp.
 8. The unit load of claim 1, wherein the separable edge protector comprises a material selected from plastic, a fiber-resin composite, fiberglass, and metal.
 9. The unit load of claim 1, wherein the zone of weakness is produced by perforations.
 10. The unit load of claim 1, wherein the zone of weakness is produced by one of laser ablation, mechanical ablation, water jets, or chemical means.
 11. A unit load comprising: a plurality of products stacked in a plurality of rows with a break formed between adjacent rows of products, the plurality of rows being aligned to define corners of the unit load; and a plurality of separable edge protectors attached at the corners of the unit load, the separable edge protectors each having a length that spans at least two rows of products and each comprising two legs joined at an apex extending along the length thereof and having one or more zones of weakness positioned such that each zone of weakness is proximate to one of the breaks between the rows of products.
 12. The unit load of claim 11, wherein the separable edge protectors are attached at the corners of the unit load by an adhesive fixing the separable edge protectors to products in the unit load.
 13. The unit load of claim 11, wherein the separable edge protectors are attached at the corners of the unit load at least in part by an overwrap.
 14. The unit load of claim 11, wherein the separable edge protectors are attached at the corners of the unit load at least in part by strapping.
 15. The unit load of claim 11, wherein each of the plurality of separable edge protectors is substantially free of zones of weakness other than those proximal to the breaks between the rows of product.
 16. A method for protecting a unit load having a plurality of rows of product containers comprising: (a) attaching one or more separable edge protectors each comprising a zone of weakness to the outer surface of the product containers in the unit load, the one or more separable edge protectors spanning at least two rows of product in the unit load, a break being defined between two adjacent rows of the at least two rows of product, the break being proximal to the zone of weakness in each of the one or more separable edge protectors; and (b) applying a force to the uppermost row of the two adjacent rows to cause separation of the uppermost row from the remaining of the two adjacent rows, wherein the force causes the one or more separable edge protectors to detach in the zone of weakness proximal to the break, leaving a remaining portion of each of the one or more separable edge protectors in place to continue providing edge protection for the remaining rows of product in the unit load.
 17. The method of claim 16, further comprising applying an overwrap to the unit load after attaching the one or more separable edge protectors to the outer surface of the product containers in the unit load.
 18. The method of claim 17 wherein the overwrap is adapted to split substantially at the break in response to applying the force.
 19. The method of claim 18 wherein the overwrap is selected from stretch wrap and shrink wrap.
 20. A method for customizing separable edge protectors for a customer, comprising: (a) receiving product information from a customer for a planned unit load identifying the elevations in the unit load of one or more breaks between rows of a stack of products, (b) preparing customized separable edge protectors having zones of weakness corresponding to the elevations in the unit load when the separable edge protectors are in place on an outer surface of the unit load, and (c) delivering the customized separable edge protectors for use in a packaging facility.
 21. The method of claim 20, further comprising (d) applying one or more customized separable edge protectors to a stack of the products to form a protected unit load.
 22. The method of claim 21, wherein the zones of weakness are substantially aligned with the breaks in the unit load.
 23. The method of claim 21, further comprising (e) applying an overwrap to the unit load.
 24. The method of claim 23, further comprising (f) removing a row of products from the unit load, wherein the act of removing causes fracture of the separable edge protectors at a zone of weakness proximal to the break beneath the removed row of products.
 25. The method of claim 24, wherein the overwrap splits substantially at the break beneath the removed row of products during the act of removing. 